Cutting Force and Surface Roughness Prediction of Al 6065 T6 during Turning Operation using Response Surface Methodology, Machine Learning and Simulation-Based Approach

ILESANMI Afolabi Daniyan^1*Lanre Daniyan²Adefemi Adeodu³Humbulani Simon Phuluwa⁴

• ¹Bells University of Technology Department of Mechatronics Engineering, Ota, Nigeria
• ²University of Nigeria, Nsukka, Nigeria
• ³Bells University of Technology, Ota, Nigeria
• ⁴University of South Africa, Pretoria, South Africa

The dynamic of cutting operation necessitates the use of reliable predictive model for accurate prediction of machining parameters namely cutting force (CF) and surface roughness (SR). This study predicts the cutting force and surface roughness of Al 6065 T6 during turning operation using a combined approach namely Surface Response Methodology (RSM), Machine Learning (ML), and computer aided simulation based approach. The RSM was conducted in the Design Expert 2022 environment producing 20 experimental trials. The computer aided modelling of the turning process was done in the Complete Abaqus Environment (CAE) while the ML technique was carried out in the Orange software environment using six ML models. To validate the experimental trials, turning operation was carried out on a centre lathe (type CTX 310 eco DMG) using carbide turning inserts as the cutting tool. The process parameters and the measured responses serve as the input into the ML model. The values of the process parameters that produced the least SR (1.02 𝜇𝑚) are cutting speed (125 m/min), feed rate (0.4 mm/rev) and depth of cut (0.75 mm). The simulation result shows slight variation in the strain profile of the workpiece which indicates slight SR. The feed rate (FR) had the highest influence on the magnitude of the CF and SR followed by the cutting speed (CS) while the depth of cut (DoC) had the least influence. The outcome of this study demonstrates the feasibility of deploying an integrated approach for investigating the critical machining parameters such as CF and SR.